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Proper Procedure for Replacing the Intelligence Modules in any Single-phase Symmetra UPS

Issue

What is the proper procedure for replacing the intelligence module in a single phase Symmetra UPS system?

Product Line

Symmetra Power Array
Symmetra RM
Symmetra LX

Environment

All serial ranges

Cause

The presence and integrity of the intelligence modules is critical for proper UPS operation. This document discusses the recommended procedure for installing or replacing intelligence modules in a single phase Symmetra UPS system.

Resolution

The following text describes the recommended procedure for use when replacing intelligence modules.

Important Note: This article should be fully read before attempting to replace modules. Consult APC technical support if unfamiliar or uncomfortable with this procedure. If behavior unlike what is documented here is observed, APC technical support should be contacted. Failure to properly install intelligence modules could result in a disruption of power to the load.

Important Note: When replacing both intelligence modules in any single phase Symmetra UPS, the user should never remove both intelligence modules at the same time even with the UPS in Maintenance Bypass. Removing both modules at the same time prohibits the replacement modules from copying the existing settings of the UPS system. This could result in undesired operation of the UPS or inappropriate power being supplied to the load. Please adhere to the following procedures when replacing intelligence modules in any Symmetra UPS system.

Important Note: If at any time during service there are issues with mechanical fit or condition of the intelligence modules, do not continue. Do not use undue or excessive force to seat modules into slots. If any difficulty is encountered, new intelligence modules should be obtained before continuing the service.

1.) On most Symmetra systems, the display interface connects to one of the intelligence modules via a cat5 UTP patch cable. This cable should be disconnected from the intelligence module to which the display connects. If the UPS being serviced is a Symmetra Power Array (Masterframe or Miniframe) this will not be necessary.

2.) While intelligence modules are hot-swappable, it is recommended that the UPS be placed in Maintenance Bypass before installing a replacement. The UPS can be placed in maintenance bypass by performing the following steps.

Command the UPS into bypass using the display interface or other accessory (e.g. network management card).

Note: The input requirements for command bypass are rather stringent. If the UPS input and output voltage do not match or are not in phase, the UPS may refuse to move to bypass mode. If that is the case, the UPS will need to be placed in Maintenance Bypass directly via the physical Maintenance Bypass switch.

Close the Maintenance Bypass switch.

3.) Locate the failed intelligence module and remove it. The failed intelligence module can be identified by a solid red LED illuminated on the intelligence module's LED array. The failed intelligence module can also be identified via the display interface or network management card.

4.) Install the replacement intelligence module and allow it several seconds to boot. If the replacement module is being installed in the bottom intelligence module slot, the user should wait for this module to assume control before proceeding.

Symmetra LX will indicate which intelligence module is in control by illuminating an additional green LED on the far left of the LED array. Non-LX systems such as Power Array and Symmetra RM 12kVA and 6kVA systems indicate that the main intelligence module has assumed control when the orange LED on the redundant intelligence module has extinguished.

5.) If both intelligence modules require replacement, remove the other module and install the replacement. If the replacement module is being installed in the bottom intelligence module slot, the user should wait for this module to assume control before proceeding.

Symmetra LX will indicate which intelligence module is in control by illuminating an additional green LED on the far left of the LED array. Non-LX systems such as Power Array and Symmetra RM 12kVA and 6kVA systems indicate that the main intelligence module has assumed control when the orange LED on the redundant intelligence module has extinguished.

6.) If the display interface was disconnected, reconnect it and wait for it to boot. Confirm that there are no faults reported by the system.

Note: If there are faults present, please contact APC support.

7.) Verify that the UPS is detecting the input voltage properly.

Note: If input voltage is not properly detected, exiting bypass may result in a loss of power to the connected equipment. If the input is not properly recognized, please contact APC technical support.

8.) Take the UPS out of maintenance bypass by opening the Maintenance Bypass switch on the UPS. The UPS will exit bypass after several seconds and may run a self-test. After approximately one minute, the UPS should be online.

Note: If the UPS is showing fault, exiting bypass may result in a loss of power to the connected equipment. If any faults are present, please contact APC technical support.